熔融纺丝高速卷绕机复杂转子系统动力学研究
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摘要
熔融纺丝高速卷绕机是整个长丝生产的关键设备,目前国产高速卷绕机与国外同类产品相比仍有一定差距,尤其表现在高速卷绕头的动力学性能方面。高速卷绕头是高速卷绕机的核心,是由锭轴夹头和卷装构成的一个变质量、变刚度、变转速的柔性支撑悬臂细长薄壁高速复杂转子系统。
本文结合上海市科委立项项目(高速卷绕机的设计制造与关键技术研究)、与高速卷绕机生产企业合作对高速卷绕头(卷绕线速度5500m/min以上、锭轴长度1500mm)系统的动态性能进行研究,为高速卷绕头的自主设计提供相关理论技术指导。
本文采用理论建模、动态仿真和试验测试相结合的方法对高速卷绕头时变系统进行动力学研究。主要工作如下：
1、考虑卷装变质量、变转动惯量和“O”型橡胶圈频变支撑刚度特性,运用空间梁单元、质量单元和弹簧单元对高速卷绕头进行理论建模,并给出可适应时变振动系统动力学方程求解的改进算法。
仿真得出：过盈联接可按固结方式简化,转动件和非转动件可简化为空间梁单元。而轴承和“O”型橡胶圈可简化为具有等效弹簧和阻尼的弹簧单元,卷装可简化为质量单元。建模得到一个考虑剪切变形对横向位移的影响,计入轴向变形与横向变形的影响,引入卷装变质量变转动惯量,考虑“O”型橡胶圈频变支撑刚度的变质量、变刚度、变转速高速卷绕头时变振动系统有限元数学模型。改进Newmark法,以适应高速卷绕头时变振动系统动力学方程的求解。
2、考虑陀螺效应和“O”型橡胶圈频变支撑刚度特性,计算分析了高速卷绕头在“空卷”和“满卷”两特定状态下时不变参数系统动态特性,并进行了相应分析比较。
从而得出：高速卷绕头工作过程中不存在像定常系统那样恒定不变的固有频率与振形；陀螺效应对满卷状态高速卷绕头的同步临界转速影响较大,而对空卷状态的同步涡动临界转速影响较小；“O”型橡胶圈的频变特性在高速卷绕头宽频转速(4547～14252r/min)工作范围内的动力学分析中不可忽略。高速卷绕头全工作过程的动态性能并非针对某一“定卷状态”进行分析就能获得,实际研究需全面考虑其变质量、变刚度、变转速的时变特性。
3、考虑高速卷绕头系统变质量、变刚度、变转速的时变特性,对其空卷启动、恒线速度卷绕(恒线速度变转速转动)和满卷停止全工作过程动态响应进行计算仿真,分析了其响应峰值速度特性：
当高速卷绕头空卷状态以不同等角加速启动时,不平衡激励的频变快慢对空卷高速卷绕头启动过程响应幅频曲线峰值所对应临界转速大小无明显影响；当高速卷绕头在不平衡质量的激励下空卷启动、恒线速度卷绕和满卷停止工作时,其全工作过程中最大不平衡响应峰值转速对应在空卷启动过程的最高转速,这为目前该型高速卷绕头仅针对空卷状态进行有效动平衡即可满足高速卷绕头全工作过程运转稳定要求,提供了可靠的理论依据。
4、在专用动平衡机上对空卷状态高速卷绕头进行动平衡,在高速卷绕头样机上对空卷状态启动、稳定高速、停车三阶段过程进行动态响应测试分析,并与对应动力学模型计算结果进行了验证。
动平衡试验中得到与理论计算结果对应的空卷状态高速卷绕头临界转速点；响应测试结果表明动态启动激励快慢即等角加速度角大小对空卷高速卷绕头启动响应的影响与理论分析基本一致,引起高速卷绕头振动的主要原因是其转子系统的不平衡。通过以上试验结果验证本文理论模型是可行的、有效的,能反映工程实际。
5、对高速卷绕头系统及其组成部件主要参数的关系进行研究,分析其影响,综合考虑给出了高速卷绕头进一步自主设计指导。
分析薄壁筒管(白套)、细长驱动轴、轴承支承位置调节、“O”型橡胶圈及悬臂支撑架等零部件相关参数与高速卷绕头系统的动态响应关系,得出在不改变高速卷绕头现有装配结构的前提下,可通过把薄壁筒管材料替换为碳纤维复合材料,减小悬臂支撑架外端“O”型橡胶圈的个数以减小其支撑刚度,增大悬臂支承架的壁厚来改善高速卷绕头系统的动态响应,综合优化以上参数对改善高速卷绕头系统的动态响应效果更明显。
本文创新点在于：
考虑变质量、变刚度、变转速特性,建立了一个包括卷装变质量变转动惯量、“O”型橡胶圈频变支撑刚度的高速卷绕头时变系统动力学模型,并给出了可适应时变振动系统动力学方程求解的改进算法。
按实际工况,全面研究了高速卷绕头空卷启动、恒线速度变转速卷绕和满卷停止整个工作过程时变系统动态性能,并通过分析计算关键点在整个工作过程的动态响应幅频特性曲线,发现：高速卷绕头全工作过程中最大不平衡响应峰值转速对应在空卷启动过程的最大转速,这为目前该型高速卷绕头只针对空卷状态进行有效动平衡提供了可靠的理论依据。
研究了高速卷绕头系统及其组成部件主要参数的关系,分析了其对卷绕过程动态响应性能影响,给出了高速卷绕头进一步自主设计指导,包括在满足工程结构要求条件下通过把薄壁筒管材料替换为碳纤维复合材料,减小悬臂支撑架外端“o”型橡胶圈的个数以降低其支撑刚度,增大悬臂支撑架的壁厚等,均可有效改善高速卷绕头系统的动态响应性能。
High-speed melt spinning winding machine play the key role in filament production process. Currently, home-made high-speed winding machine still lags far behind compared with similar overseas products, especially in the dynamic performance of the high-speed winder. As the core of the high-speed winding machine, the high-speed winder is essentially a complex high-speed thin-walled rotor system with long and thin flexible cantilever, which is mass-variable, stiffness-variable, and rotation-speed-variable. It is composed of a spindle chuck and several filament packages.
As the proposed project of Shanghai Science and Technology Commission, the dynamic performance of the high-speed winder is studied in this thesis so as to provide related theoretical and technical guidance for the design of high-speed winder (the winding linear velocity is above5500m/min, the length of spindle isl500mm). Cooperation of the high-speed winding machine manufacturers is acknowledged.
Theoretical modeling, dynamics simulation and experimental testing methods are adopted in this thesis in the dynamic research of the time varying system of high-speed winder. The main contents include:
1. Theoretical modeling of high-speed winder considering the variable mass, variable rotary inertia and frequency-independent stiffness of "O" type rubber ring is developed by using space beam element, mass element and spring element. Moreover, an improved Newmark method is provided which is adaptable to solutions of time-varying vibration system dynamics equation.
It can be concluded from the simulation that interference fit connection can be simplified as consolidation; rotating parts and non-rotating parts can be simplified as space beam element. Bearing and "O" type rubber ring can be simplified to equivalent spring and damping spring element, and packages can be simplified as the mass element. Considering the effect of shear deformation on lateral displacement and the effect of axial deformation and lateral deformation, variable mass and variable rotary inertia of package are integrated in the finite-element model which described the time varying vibration system of high-speed winder with variable mass, variable stiffness and variable rotation speed. The frequency-independent stiffness of "O" type rubber ring is considered as well. Newmark method is improved so as to adapt to the solution of the time-varying vibration dynamic equation of high-speed winder.
2. Considering the gyroscopic effect and the frequency-independent stiffness of "O" type rubber ring, the time-invariant system, which describes the dynamic performance of the high-speed winder under "empty package" and "full package" condition, is analyzed, and corresponding comparison is made.
It is concluded that unlike the constant system, the high-speed winder has constant natural frequencies and modes of vibration during the working process; gyroscopic effect has a greater influence on the synchronous critical speed of high-speed winder under full package state, with a smaller influence on the synchronous eddying motion critical speed under empty package state; frequency-dependent characteristics of "O" type rubber ring should not be neglected in the dynamic analysis within the scope of work of broadband speed (4547-14252r/min) of high-speed winder. The dynamic performance of high-speed winder during the entire working process cannot be predicted by analyzing a certain "fixed package state". Time varying characteristics of high-speed winder, such as variable mass, variable stiffness and variable rotation speed should be fully considered.
3. Considering the time varying characteristics, such as variable mass, variable stiffness and variable rotation speed, the dynamic response of the entire working process including the high-speed winder starting from the empty package, evolving to winding at constant linear velocity (rotate at constant linear velocity and variable rotation speed), and ending at full package is calculated and simulated. The peak speed characteristics of the response are analyzed as well.
When the high-speed winder starts with different isogonism accelerations under empty package, speed of frequency change of unbalance excitation has no significant effect on the critical speed corresponding to the peak value on the amplitude frequency diagram; when the high-speed winder starts up at empty package, winds at constant linear velocity and stops working at full package under excitation by unbalanced mass, the maximum unbalanced response peak speed during the entire working process corresponds to the maximum speed during the starting process at empty package. This provides theoretical verification for the fact that conducting effective dynamic balance in empty package state stables operation of high-speed winder during the whole working process.
4. Conduct dynamic balance on high-speed winder with special dynamic balancing machine under empty package condition and dynamic response test analysis on high-speed winder model machine. Dynamic response test analysis of the entire processes, namely starting, stabilizing in the speed, and stopping is made. The results are verified by comparison with that predicted by the corresponding dynamic model.
Critical speed of high-speed winder in empty package has been obtained in the dynamic balance experiment; this is coordinated with the theoretical calculation. Response test result shows that the theoretical analysis well predicts the effect of the speed of dynamic starting excitation, namely the angle of isogonal acceleration, on the starting response of high-speed winder under empty package. The primary reason for the vibration of high-speed winder is imbalance of the rotor system. The above experiments results prove that the theoretical model established in this thesis is accurate, effective and well explain the practical phenomenon.
5. Study the relationship between high-speed winder system and primary parameters of its parts, and analyze the influence based on the relationship, then provide guidance for the design of high-speed winder after comprehensive consideration.
By analyzing the relationship between the parameters with regard to the thin-walled bobbin, long and thin driving shaft, changing the position of bearing,"O" type rubber ring, the cantilever frame together other components and dynamic response of the high-speed winder, it can be concluded that the dynamic response of high-speed winder system can be improved by the following operations:1. reducing the supporting stiffness of "O" type rubber ring at the outer end of the cantilever by changing the number of "O" type rubber ring;2.increasing the wall thickness of the cantilever;3. employing carbon fiber composite instead of the thin-walled bobbin without changing the original assembly structure. Optimizing the above parameters comprehensively is better for improving the dynamic response of the high-speed winder system.
Innovation in this thesis lies in:
Based on variable mass, variable stiffness and variable rotation speed, a dynamic model of the time varying system of the high-speed winder including packages with variable mass and variable rotary inertia and "O" type rubber ring with frequency-dependent stiffness is developed.
through analysis on the amplitude frequency characteristics of the dynamic response of of key positions of the high-speed winder in the entire working process, it is found that the maximum unbalance response peak speed corresponds to the maximum speed in the starting process under empty package, which provides theoretical basis for the fact that the high-speed winder conducts effective dynamic balance in empty package state.
Study the relationship between high-speed winder system and primary parameters of its parts, and analyze the influence based on the relationship, it provides guidance for independent design of high-speed winder. By employing the carbon fiber composite instead of the thin-walled bobbin material, the supporting stiffness of "O" type rubber ring at the outer end of the cantilever frame can be reduced by changing the number of "O" type rubber ring, and the wall thickness of the cantilever can be increased to improve the dynamic response of high-speed winder system.
本文结合上海市科委立项项目(高速卷绕机的设计制造与关键技术研究)、与高速卷绕机生产企业合作对高速卷绕头(卷绕线速度5500m/min以上、锭轴长度1500mm)系统的动态性能进行研究,为高速卷绕头的自主设计提供相关理论技术指导。
本文采用理论建模、动态仿真和试验测试相结合的方法对高速卷绕头时变系统进行动力学研究。主要工作如下：
1、考虑卷装变质量、变转动惯量和“O”型橡胶圈频变支撑刚度特性,运用空间梁单元、质量单元和弹簧单元对高速卷绕头进行理论建模,并给出可适应时变振动系统动力学方程求解的改进算法。
仿真得出：过盈联接可按固结方式简化,转动件和非转动件可简化为空间梁单元。而轴承和“O”型橡胶圈可简化为具有等效弹簧和阻尼的弹簧单元,卷装可简化为质量单元。建模得到一个考虑剪切变形对横向位移的影响,计入轴向变形与横向变形的影响,引入卷装变质量变转动惯量,考虑“O”型橡胶圈频变支撑刚度的变质量、变刚度、变转速高速卷绕头时变振动系统有限元数学模型。改进Newmark法,以适应高速卷绕头时变振动系统动力学方程的求解。
2、考虑陀螺效应和“O”型橡胶圈频变支撑刚度特性,计算分析了高速卷绕头在“空卷”和“满卷”两特定状态下时不变参数系统动态特性,并进行了相应分析比较。
从而得出：高速卷绕头工作过程中不存在像定常系统那样恒定不变的固有频率与振形；陀螺效应对满卷状态高速卷绕头的同步临界转速影响较大,而对空卷状态的同步涡动临界转速影响较小；“O”型橡胶圈的频变特性在高速卷绕头宽频转速(4547～14252r/min)工作范围内的动力学分析中不可忽略。高速卷绕头全工作过程的动态性能并非针对某一“定卷状态”进行分析就能获得,实际研究需全面考虑其变质量、变刚度、变转速的时变特性。
3、考虑高速卷绕头系统变质量、变刚度、变转速的时变特性,对其空卷启动、恒线速度卷绕(恒线速度变转速转动)和满卷停止全工作过程动态响应进行计算仿真,分析了其响应峰值速度特性：
当高速卷绕头空卷状态以不同等角加速启动时,不平衡激励的频变快慢对空卷高速卷绕头启动过程响应幅频曲线峰值所对应临界转速大小无明显影响；当高速卷绕头在不平衡质量的激励下空卷启动、恒线速度卷绕和满卷停止工作时,其全工作过程中最大不平衡响应峰值转速对应在空卷启动过程的最高转速,这为目前该型高速卷绕头仅针对空卷状态进行有效动平衡即可满足高速卷绕头全工作过程运转稳定要求,提供了可靠的理论依据。
4、在专用动平衡机上对空卷状态高速卷绕头进行动平衡,在高速卷绕头样机上对空卷状态启动、稳定高速、停车三阶段过程进行动态响应测试分析,并与对应动力学模型计算结果进行了验证。
动平衡试验中得到与理论计算结果对应的空卷状态高速卷绕头临界转速点；响应测试结果表明动态启动激励快慢即等角加速度角大小对空卷高速卷绕头启动响应的影响与理论分析基本一致,引起高速卷绕头振动的主要原因是其转子系统的不平衡。通过以上试验结果验证本文理论模型是可行的、有效的,能反映工程实际。
5、对高速卷绕头系统及其组成部件主要参数的关系进行研究,分析其影响,综合考虑给出了高速卷绕头进一步自主设计指导。
分析薄壁筒管(白套)、细长驱动轴、轴承支承位置调节、“O”型橡胶圈及悬臂支撑架等零部件相关参数与高速卷绕头系统的动态响应关系,得出在不改变高速卷绕头现有装配结构的前提下,可通过把薄壁筒管材料替换为碳纤维复合材料,减小悬臂支撑架外端“O”型橡胶圈的个数以减小其支撑刚度,增大悬臂支承架的壁厚来改善高速卷绕头系统的动态响应,综合优化以上参数对改善高速卷绕头系统的动态响应效果更明显。
本文创新点在于：
考虑变质量、变刚度、变转速特性,建立了一个包括卷装变质量变转动惯量、“O”型橡胶圈频变支撑刚度的高速卷绕头时变系统动力学模型,并给出了可适应时变振动系统动力学方程求解的改进算法。
按实际工况,全面研究了高速卷绕头空卷启动、恒线速度变转速卷绕和满卷停止整个工作过程时变系统动态性能,并通过分析计算关键点在整个工作过程的动态响应幅频特性曲线,发现：高速卷绕头全工作过程中最大不平衡响应峰值转速对应在空卷启动过程的最大转速,这为目前该型高速卷绕头只针对空卷状态进行有效动平衡提供了可靠的理论依据。
研究了高速卷绕头系统及其组成部件主要参数的关系,分析了其对卷绕过程动态响应性能影响,给出了高速卷绕头进一步自主设计指导,包括在满足工程结构要求条件下通过把薄壁筒管材料替换为碳纤维复合材料,减小悬臂支撑架外端“o”型橡胶圈的个数以降低其支撑刚度,增大悬臂支撑架的壁厚等,均可有效改善高速卷绕头系统的动态响应性能。
High-speed melt spinning winding machine play the key role in filament production process. Currently, home-made high-speed winding machine still lags far behind compared with similar overseas products, especially in the dynamic performance of the high-speed winder. As the core of the high-speed winding machine, the high-speed winder is essentially a complex high-speed thin-walled rotor system with long and thin flexible cantilever, which is mass-variable, stiffness-variable, and rotation-speed-variable. It is composed of a spindle chuck and several filament packages.
As the proposed project of Shanghai Science and Technology Commission, the dynamic performance of the high-speed winder is studied in this thesis so as to provide related theoretical and technical guidance for the design of high-speed winder (the winding linear velocity is above5500m/min, the length of spindle isl500mm). Cooperation of the high-speed winding machine manufacturers is acknowledged.
Theoretical modeling, dynamics simulation and experimental testing methods are adopted in this thesis in the dynamic research of the time varying system of high-speed winder. The main contents include:
1. Theoretical modeling of high-speed winder considering the variable mass, variable rotary inertia and frequency-independent stiffness of "O" type rubber ring is developed by using space beam element, mass element and spring element. Moreover, an improved Newmark method is provided which is adaptable to solutions of time-varying vibration system dynamics equation.
It can be concluded from the simulation that interference fit connection can be simplified as consolidation; rotating parts and non-rotating parts can be simplified as space beam element. Bearing and "O" type rubber ring can be simplified to equivalent spring and damping spring element, and packages can be simplified as the mass element. Considering the effect of shear deformation on lateral displacement and the effect of axial deformation and lateral deformation, variable mass and variable rotary inertia of package are integrated in the finite-element model which described the time varying vibration system of high-speed winder with variable mass, variable stiffness and variable rotation speed. The frequency-independent stiffness of "O" type rubber ring is considered as well. Newmark method is improved so as to adapt to the solution of the time-varying vibration dynamic equation of high-speed winder.
2. Considering the gyroscopic effect and the frequency-independent stiffness of "O" type rubber ring, the time-invariant system, which describes the dynamic performance of the high-speed winder under "empty package" and "full package" condition, is analyzed, and corresponding comparison is made.
It is concluded that unlike the constant system, the high-speed winder has constant natural frequencies and modes of vibration during the working process; gyroscopic effect has a greater influence on the synchronous critical speed of high-speed winder under full package state, with a smaller influence on the synchronous eddying motion critical speed under empty package state; frequency-dependent characteristics of "O" type rubber ring should not be neglected in the dynamic analysis within the scope of work of broadband speed (4547-14252r/min) of high-speed winder. The dynamic performance of high-speed winder during the entire working process cannot be predicted by analyzing a certain "fixed package state". Time varying characteristics of high-speed winder, such as variable mass, variable stiffness and variable rotation speed should be fully considered.
3. Considering the time varying characteristics, such as variable mass, variable stiffness and variable rotation speed, the dynamic response of the entire working process including the high-speed winder starting from the empty package, evolving to winding at constant linear velocity (rotate at constant linear velocity and variable rotation speed), and ending at full package is calculated and simulated. The peak speed characteristics of the response are analyzed as well.
When the high-speed winder starts with different isogonism accelerations under empty package, speed of frequency change of unbalance excitation has no significant effect on the critical speed corresponding to the peak value on the amplitude frequency diagram; when the high-speed winder starts up at empty package, winds at constant linear velocity and stops working at full package under excitation by unbalanced mass, the maximum unbalanced response peak speed during the entire working process corresponds to the maximum speed during the starting process at empty package. This provides theoretical verification for the fact that conducting effective dynamic balance in empty package state stables operation of high-speed winder during the whole working process.
4. Conduct dynamic balance on high-speed winder with special dynamic balancing machine under empty package condition and dynamic response test analysis on high-speed winder model machine. Dynamic response test analysis of the entire processes, namely starting, stabilizing in the speed, and stopping is made. The results are verified by comparison with that predicted by the corresponding dynamic model.
Critical speed of high-speed winder in empty package has been obtained in the dynamic balance experiment; this is coordinated with the theoretical calculation. Response test result shows that the theoretical analysis well predicts the effect of the speed of dynamic starting excitation, namely the angle of isogonal acceleration, on the starting response of high-speed winder under empty package. The primary reason for the vibration of high-speed winder is imbalance of the rotor system. The above experiments results prove that the theoretical model established in this thesis is accurate, effective and well explain the practical phenomenon.
5. Study the relationship between high-speed winder system and primary parameters of its parts, and analyze the influence based on the relationship, then provide guidance for the design of high-speed winder after comprehensive consideration.
By analyzing the relationship between the parameters with regard to the thin-walled bobbin, long and thin driving shaft, changing the position of bearing,"O" type rubber ring, the cantilever frame together other components and dynamic response of the high-speed winder, it can be concluded that the dynamic response of high-speed winder system can be improved by the following operations:1. reducing the supporting stiffness of "O" type rubber ring at the outer end of the cantilever by changing the number of "O" type rubber ring;2.increasing the wall thickness of the cantilever;3. employing carbon fiber composite instead of the thin-walled bobbin without changing the original assembly structure. Optimizing the above parameters comprehensively is better for improving the dynamic response of the high-speed winder system.
Innovation in this thesis lies in:
Based on variable mass, variable stiffness and variable rotation speed, a dynamic model of the time varying system of the high-speed winder including packages with variable mass and variable rotary inertia and "O" type rubber ring with frequency-dependent stiffness is developed.
through analysis on the amplitude frequency characteristics of the dynamic response of of key positions of the high-speed winder in the entire working process, it is found that the maximum unbalance response peak speed corresponds to the maximum speed in the starting process under empty package, which provides theoretical basis for the fact that the high-speed winder conducts effective dynamic balance in empty package state.
Study the relationship between high-speed winder system and primary parameters of its parts, and analyze the influence based on the relationship, it provides guidance for independent design of high-speed winder. By employing the carbon fiber composite instead of the thin-walled bobbin material, the supporting stiffness of "O" type rubber ring at the outer end of the cantilever frame can be reduced by changing the number of "O" type rubber ring, and the wall thickness of the cantilever can be increased to improve the dynamic response of high-speed winder system.
引文
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